Ferro-concrete molding process

ABSTRACT

THIS INVENTION IS A MOLDING PROCESS UTILIZING THE COMBINATION OF LAYERS OF REINFORCING MATERIAL AND CONCRETE TO ACHIEVE A NEW AND NOVEL FERRO-CONCRETE PRODUCT. MORE PARTICULARLY, THIS INVENTION IS A MOLDING PROCESS FOR CREATING FERRO-CONCRETE STRUCTURES IN A MANNER WHEREUPON THE REINFORCING MATERIAL IS EASILY AND EFFECTIVELY ANCHORED IN A COMPACT MANNER BEFORE APPLYING THE CONCRETE MATERIAL THERETO SO AS TO ACHIEVE THE MAXIMUM STRENGTH REQUIRING A MINIMUM AMOUNT OF TIME AND RESULTANT MATERIAL THICKNESS.

Dec. 5, 1972 c. D. MATTINGLY 3,705,228

FERRO- CONCRETE MOLDING PROCES S Filed Nov. 10, 1969 i N VENTOR.

C HARLES D. MATTINGLY United States Patent 3,705,228 FERRO-CONCRETE MOLDING PROCESS Charles D. Mattingly, Wichita, Kans, assignor to Mattingly, Inc., Wichita, Kans.

Filed Nov. 10, 1969, Ser. No. 875,076 Int. Cl. B28b 1/32, 23/02 US. Cl. 264-256 6 Claims ABSTRACT OF THE DISCLOSURE The art of manufacturing items through the use of a ferro-concrete process is long known in the art whereupon layers of reinforcing rod, mesh, and pipe material are layed upon each other and covered by a concrete material through a trowelling or gunite process. The end product is a ferro-concrete structure being a combination of reinforcing and portland cement whereupon the resultant product is stronger than the sum of its components. In fact, it has been known that the use of ferroconcrete is economical and desirable when constructing barges and ships which are greater than approximately 30 feet in length. Additionally, the use of ferro-concrete material in the boat building industry has long been recognized as very beneficial whereupon great strength is achieved; the material is resistant to weathering features; the hulls become stronger with age; and repairs can be readily made to the structure if damaged by running into rocks, coral reefs, etc.

The prior art processes of producing items through the use of a ferro-concrete material normally utilizes the steps of (1) construction of an elaborate frame of welded galvanized pipe or other such material; (2) then having the layers of wire mesh and/or reinforcing rod secured to the initial frame structure; and (3) finally the concrete material is added to the frame through a gunite or trowelling process. However, it is seen that such construction of an initial frame structure takes considerable man hours and, therefore, is costly and difficult to duplicate. Another method of utilizing ferro-coucrete material is applying an interconnected metal reinforcing frame work to the outer surface of the mold structure and then applying the plaster or concrete material thereto. It is noted in the prior art processes that numerous problems are encountered in placing the layers of mesh material within certain boundaries to achieve uniform thickness so as to cover the mesh material completely with the concrete material. In fact, any exposure of the reinforcing mesh material to the atmosphere creates possible corrosion problems which area must be repaired in a hand manner thereby being very costly.

In one preferred embodiment of this invention, a ferroconcrete molding process is provided in order to simplify the method of construction plus achieve a finished product having a smooth, durable finished surface. More particularly, the molding process of this invention involves the steps of (1) utilizing a given mold structure whether being for manufacture of a barge, an automobile body, yacht, or the like; (2) applying a first adhesive resin surface to the mold structure in an even manner of the type which will later dry to a hardened, smooth polished finish;

(3) applying a layer of wrinkled anchor reinforcing material such as a mesh material having a portion of the same embodied within the adhesive material and another portion exposed to form loop or hook type elements; (4) awaiting for proper setting of the adhesive material to a hardened integral structure having the reinforcing mesh material rigidly attached thereto; (5) placing a plurality of layers of reinforcing material such as reinforcing bar, wire mesh material, and/or screen material against the first anchor reinforcement material; (6) securing the second layers of reinforcing material by tying wires to the first anchor reinforcing material so as to present an overall compact structure of uniform thickness; (7) applying concrete material to the interconnected layers of reinforcing material; (8) if necessary, vibrating the concrete material so as to achieve uniform coverage within the reinforcing material and uniform thickness; (9) curing of the concrete material to achieve the proper strength; and (10) removing of the finished product from the mold structure being an integral structure of uniform thickness with maximum strength and an outer hardened finished surface. It is to be noted that the molding process of this invention overcomes the problems of placing the layers reinforcing material in the desired planes to maintain a compact thickness which is achieved through the use of the tying wires of this invention.

One object of this invention is to provide a molding process for construction of ferro-concrete overcoming the aforementioned disadvantages of the prior art processes.

Another object of this invention is to provide a molding process for use in construction of ferro-concrete products whereupon means are provided for readily attaching layers of reinforcing material in a most compact manner to a given mold surface.

Another object of this invention is to provide a ferroconcrete molding process operable to secure an anchor layer of reinforcing material to an adhesive material layer to achieve an outer finished surface of desired hardness, predetermined color, and corrosion resistance.

One other object of this invention is to provide a ferroconcrete molding process with steps that are easy to follow and results in substantial savings in construction time and, therefore, achieves great monetary savings.

Various other objects, advantages, and features of the invention will become apparent to those skilled in the art from the following discussion, taken in conjunction with the accompanying drawings, in which:

FIG. 1 is a perspective view of a mold structure illustrating the first step of the molding process of this invention as applying an adhesive material thereto;

FIG. 2 is a fragmentary perspective view of the new mold structure similar to FIG. 1 illustrating the second step of the molding process of applying an initial anchor reinforcing material thereto;

FIG. 3 is an enlarged fragmentary sectional view taken along line 33 in FIG. 2;

'FIG. 4 is a fragmentary sectional view similar to FIG. 3 illustrating tying wires connected thereto;

FIG. 5 is a fragmentary perspective view illustrating the initial anchor reinforcing members being secured through the tying wires to the other multiple layers of reinforcing material; and

FIG. 6 is a sectional view similar to FIG. 3 having the concrete material applied thereto through a granite process.

The following is a discussion and description of preferred specific embodiments of the new ferro-concrete molding process of this invention, such being made with reference to the drawings whereupon the same reference numerals are used to indicate the same or similar parts and/ or structure. It is to be understood that such discussion and description is not to unduly limit the scope of the invention.

The ferro-concrete construction business has been rapidly increasing in the past few years with the initial history and development of ferro-concrete beginning as a boat building material. In drawing comparisons with the physical properties of ferro-concrete to competitive material such as steel, the use of ferro-concrete was found far superior in such boat construction for the following main reasons:

(1) ferro-concrete has the ability to build hulls, decks, bulkheads, floors, fish tanks, and bullworks in one piece construction resulting in a monolithic structure of immense strength which actually increases with age;

(2) due to the low cost of the raw materials and the type of labor that can be employed for construction, the ferro-concrete hull would generally cost less than an equivalent hull in other material when over a certain boat length;

(3) ferro-concrete has great resistance to abrasion, will not corrode, and has proven aging properties plus being immune to marine borers, therefore, the maintenance costs with a ferro-cement hull are less than any other; and

(4) in the event of damage, it is found that ferro-concrete can be easily repaired by unskilled labor in any climatic condition except under freezing conditions.

Therefore, it is noted that ferro-concrete has many new and novel characteristics with the main problem and expense being the time consumed in building the main support frame to receive the concrete material.

Referring to the drawings in detail and in particular FIG. 1, the molding process of this invention utilizes a mold structure such as indicated at 12 which, in this case, is illustrated as a female type boat mold. However, it is obvious that any type of mold structure 12 may be used depending on the item being manufactured. In practicing the ferro-concrete molding process of this invention, it is seen that an applicator gun 14 may be operably connected to an air compressor (not shown) so as to deliver an adhesive material indicated at 16 as a coating to the inside of the mold structure 12. Another item being utilized is a woven primary or anchor reinforcing material 18 which is placed against the adhesive material 16 as shown in FIG. 2. Still other items of manufacture are a plurality of support reinforcing mesh material 20 plus tying wires 22. It is seen that the support reinforcing material 20 is composed of a plurality of layers built to a desired thickness as will become obvious. The tying wires 22 are used to anchor the support reinforcing material 20 to the primary reinforcing material 18 in a manner to be described. One final material in practicing the molding process of this invention is portland concrete material 26 which may be sprayed upon the mold structure 12 through a gunite process utilizing a discharge gun 28 in a conventional manner.

In practicing the ferro-concrete molding process of this invention, the first step is to prepare the mold structure 12 which may be easily done by applying a mold release compound or the like to the inner surface indicated at 30. This operates to permit easy removal of the finished molded product from the mold structure in a conventional manner.

The second step of the molding process is to apply to the inner surface 30 of the mold structure 12 a coating of adhesive material 16 such as epoxy resin in layer form as through the use of the applicator gun 14. The epoxy resin material 16 would be very adhesive in nature but solidifies into a smooth hardened structure and can be supplied in any desired color. The adhesive material 16 might be a polyester gel coat with the main characteristic of being an adhesive form and curing into a hardened smooth finished surface.

The third step of the molding process is to apply the primary reinforcing material 18 evenly and completely against the adhesive material I16 as shown in FIG. 3. It is noted that the first reinforcing material 1 8 is applied so that approximately 50 is buried within the adhesive material and the other 50% is exposed therefrom. More particularly, the exposed 50% portion of the primary reinforcing material 18 provides a plurality of laterally extended hook or U-shaped sections 33 for reasons to become obvious. It is to be noted that the primary reinforcing material 18 is placed against the adhesive material 16 so as to be embodied therein but not to contact the mold surface 30 of the mold structure 12. The primary reinforcing material .18 can be made of a chicken mesh material having portions laterally extended therefrom for connecting the secondary reinforcing material 20 thereto.

In order to prevent the primary reinforcing material 18 from touching the mold surface 30, the process may be altered to permit the first adhesive material 16 to cure into a hardened coat. Next, the primary reinforcing material 18 is placed against the hardened coat into a second layer of adhesive material 16 applied to the mold structure 12 to only leave the hook sections 33 exposed.

The fourth step is to await a proper time period for the curing of the adhesive material 16 so that the primary reinforcing material 18 is securely anchored thereto.

The fifth step of this invention involves training the respective tying wires 22 under respective ones of the raised hook sections 33 as shown in FIG. 4. The tying wires 22 are of any desired strong material but normally of the same material as the reinforcing.

The sixth step of the molding process of this invention is to apply the secondary layers of reinforcing material 20 against the combination of the first primary reinforcing material 18- and the adhesive material '16. It is noted that this secondary reinforcing material 20 can be a plurality of layers of mesh material, rods, strips or other types of reinforcing elements. The secondary reinforcing material 20 is adapted to add the considerable strength to the overall finished product.

The seventh step of this invention is to grasp the free ends of the tying wires 22 above the secondary reinforcing material 20 positioned therebetween so that the same may be twisted about each other to draw the secondary reinforcing material 20 downwardly into firm contact with the adhesive material 16 and the primary reinforcing material 18. It is seen that the upper ends of the tying wires 22 may be thereupon pressed downwardly so as to achieve a minimum and uniform amount of thickness between the uppermost surface of the secondary reinforcing material 20 and the adhesive material 16. It is noted that the tying wires 22 permits the easy application of the secondary reinforcing material 20 without requiring welding or the like.

The eighth step of the molding process of this invention involves the application of the portland cement mixture 26 to the anchored secondary reinforcing material 20 as shown in FIG. 6. The method being used is known as the gunite process whereupon the mixture of cement is sprayed thereon under air pressure through the dis charge gun 28.

The ninth step of the molding process of this invention involves, in most cases, the agitation of the outer surface of the concrete material 26 which is desirable to assure that the concrete material settles inwardly and completely fills and eliminates any possible voids. The concrete material 26 may be pressed therein as through a vibrator machine (not shown) or trowelled with faster results ob tained through the use of the gunite process.

The final step in the mold process after proper controlled curing of the concrete material 26 is to remove the finished boat from the mold structure 12. It is to be noted that the finished product has an outer hardened epoxy resin surface which may be constructed of any given color so that future surface finishing or maintenance as through painting or the like would not be required.

It is noted that the finished product of this process may be constructed in thickness and strength equal to sheet steel and ends up wherein the composition has a greater strength together than any of the individual elements therein taken individually. It has been found that the portland cement mixture has worked out successfully whereupon the ratio used Was 16:1 pounds of portland cement, 4:1 pounds of pozzolan (fly ash), 30:2 pounds of sand, and 35001150 cc. of water. This results in a very workable portland cement mortar Which can be easily added to the structure and readily impregnates the secondary reinforcing material. The pozzolan is a siliceous material the same as diatomaceous earth and aids in achieving greater water tightness in the finished product. Another accepted mortar mixture has been found using 50-65 lbs. of cement with a cubic foot of sand using as little water as necessary to make a workable mixture. In this case, up to 10% of the weight of cement can be substituted by pozzolan to achieve the desired results.

It is seen that the new and novel ferro-concrete molding process of this invention achieves a fast, simple production means for the mass production of duplicate ferroconcrete structures achieving (1) a means for obtaining a true surface reproduction; (2) easy convenient access to the Work surface during construction; (3) a means for shaping and securing reinforcing materials accurately in place and to designed required thickness; (4) a means of mechanically bonding securely a surface material to the fero-concrete material; and (5) an assembly process that allows the use of fast production methods of concrete application. It is seen that the molding process of this invention utilizes simple to follow steps to achieve the desired product with a controlled thickness not requiring welding or other such processes of trying to achieve a basic frame of a constant thickness.

While the invention has been described in conjunction with preferred specific embodiments thereof, it will be understood that this description is intended to illustrate the scope of the invention which is defined by the following claims.

I claim:

1. A ferro-concrete molding process adapted to produce molded structures such as barges, automobile bodies, yachts, or the like from a mold structure, comprising the following steps:

(a) applying a first, thin, adhesive resin coating layer to said mold structure,

(b) applying to said first coating layer a layer of first reinforcing material having a portion of the same embodied within said coating layer while being spaced from said mold structure and having a plurality of exposed elements extending laterally from said coating layer,

(0) awaiting for proper setting of said coating layer to a hardened integral structure having said reinforcing material rigidly attached thereto,

(d) placing a second reinforcing material against the exposed elements of said first reinforcing material,

(e) said second reinforcing material being a plurality of layers of screen material, mesh material, and reinforcing bar secured in contact with each other and said exposed first reinforcing elements to form a minimum thickness of said layers,

(f) securing said second reinforcing layers to said exposed reinforcing elements by a plurality of tying wire members so as to present an overall compact structure of uniform thickness,

(g) applying a cementitious bonding material to completely encompass said second reinforcing material, and

(h) curing said bonding material to achieve an integral molded product having great strength and a finished outer coat of said first coating layer, whereby on removing the finished product from the mold structure, an integral structure of uniform thickness with maximum strength and an outer hardened finished surface is obtained.

2. A molding process as described in claim 1, wherein:

(a) said first reinforcing material having a plurality of hook sections extended laterally from one side only of a main body which is generally in a common plan, and

(b) on anchoring said second reinforcing material to said first reinforcing material, attaching the same through a plurality of tying wire members to said first reinforcing material.

3. A molding process as described in claim 1, wherein:

said bonding material being a portland cement mixture.

4. A molding process as described in claim 1, wherein:

said cement material being a mixture of 16:1 pounds of portland cement, 4:1 pounds of pozzolan, 30:2 pounds of sand, and 3500: cc. of water.

5. A molding process as described in claim 1, wherein:

(a) said first reinforcing material having a plurality of adjacent hook sections extending laterally from one side only of a main body, and approximately 50% of said main body is buried in said first coating layer, and

(b) anchoring said second reinforcing material to said hook sections by a plurality of tying wire members in a compact, secure manner.

6. A molding process as described in claim 1, Whereas:

(a) after applying said first coating layer, curing said first coating layer, and

(b) applying a second coating layer to said hardened first coating layer and then attaching said first reinforcing material to said second coating layer.

References Cited UNITED STATES PATENTS 1,089,488 3/1914 Luten 264-34 X 2,595,123 4/1952 Callan 26435 X 3,381,066 4/1968 Lowe et al 264-256 X 2,370,638 3/ 1945 Crowe 264--LAYERS DIGEST 3,124,626 3/1964 Graham et a1 264255 X 3,217,077 11/1965 Cocke 264256 3,217,375 11/1965 Kinnard 264LAYERS DIGEST 3,324,213 6/1967 Anfinset 264--255 X ROBERT F. WHITE, Primary Examiner J. H. SILBAUGH, Assistant Examiner US. Cl. X.R.

264275, 308, 309, DIG. 57 

